I have just converted my Dana 35c using all Ford EA parts from the wreakers and it was a fully bolt on job with no welding whats so ever. I have done a full write up on my site so you all can see what is needed and all costs involved. The only thing you have to make yourself is a spacer which I show you how and give the drawing for as well.
Go to my how to section of my site at www.go.jeep-xj.info
Just finished conversion of my XJ Cherokee to XF (1986) falcon rear disks following lengthy consultation with Marcus (GoJeep).
As Marcus and I discussed quite a lot aboutthe conversion I followed a similar path to that on his website.
Mine cost a fair bit more as I chose to use new vented and slotted XF falcon rotors from disk brakes Australia.
I also had the required caliper mount spacers machined up for me and custom made some brackets from steel plate and box section so I could use stock XJ handbrake cables.
Choice of XF over EA falcon was for the thicker vented rotors and the compatibility with stock XJ handbrake cables. XF falcon hydraulic pipes are a direct fit on XJ D35 axle too when XF calipers are used.... screw straight in and have right threads and bends too.
I chose to have the rotors bored to fit the XJ axle flange rather than adjust axle to suit rotors. Difference is only about 1mm.
As it stands I can convert back to XJ brakes by just unbolting after removing the axles.
I found a HUGE improvement in normal braking and pedal feel. Pedal travel is very small for typical braking. Emergency braking is remarkably similar (better) than rear drum brake XJ... fronts still lock up first so I haven't changed the pressure proportioning valve.
I ended up changing the XF cable hole location on the caliper handbrake lever to give shorter handbrake travel at the Jeep handle. Disks hold on any slope. No more funny feel about handbrake holding forwards/backwards, I always needed more handbrake on uphills than downhills with drums. Much better handbrake "progressive" feel too.
Downside for XF falcon parts was handbrake cable outer retainer bracket must be welded to the axle tube. I also needed a thicker spacer than Marcus' EA handbrakes.
There is some discussion that EA caliper has better pads, mounting and mud sealing on slide pins too.
EA required some handbrake cable changes. Came down to vented rotors or non vented decision for me.
One hint for anyone thinking of converting. I think XJ front rotors will work on the rear with a 4mm caliper mount spacer and XF falcon calipers. Makes for four identical rotors.
XF falcon rear rotors are much beefier/bigger than Jeep XJ fronts so I chose to stick with the ford parts.
Mine passed its first mud test so far, no problems.
For anyone interested:-
Will show at SJC meet Wed 7/8.
Will post story, how to, and photos soon after.
Yea I was wondering this myself. I had a bit of a chat the the mechanic at work(ex) about this and he had the same worries. His main concern was ADR and the brake bias that may result in the conversion.
GoJeep have you had any probs with ADR or have you had an engineers' certificate issued?
Disks have always been seen as an improvement over drum brakes and are required on most V8 conversions.
I have not done anything about a engineers report as all I have shown the conversion to thought that they were always fitted from the factory like that ( inculding a brake supply place ) and are shocked to learn that they normally have drums. :eek:
My XJ that I converted to coils at the rear was inspected by the police as well as the insurance inspector and no one picked it as not being stock so they are not very wise on whats standard on these anyway. :rolleyes:
The master cylinder is the same part number between the ZJ (ZG) all disk Grand and at the most the only difference in the proportioning valve is the little spring inside. You have to remember that there was no change done to any of the braking system when a Falcon was ordered with or without rear disks as the calipers were designed to be a full replcement for the drums and why we needed no change either! ;)
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